Finite element orthogonal machining model based on Lagrangian formulation requires informations for chip separation depth in order to consider cutting edge roundness effects. This study analytically determines the chip separation depth using the minim...
Finite element orthogonal machining model based on Lagrangian formulation requires informations for chip separation depth in order to consider cutting edge roundness effects. This study analytically determines the chip separation depth using the minimum energy principle that chip separation occurs at the depth where cutting energy is minimum. Finite element analysis is employed to estimate chip formation and plowing forces separately with an assumption that primary cutting force can be decomposed into chip formation and plowing forces. Primary cutting force is obtained by superposing the chip formation and plowing forces at various separation depth. It is demonstrated that there exist a depth at which cutting energy is minimum. A finite element simulation of orthogonal machining with a round cutting edge tool is conducted using the chip separation depth predicted in the present study.